Application of BANNER ultrasonic sensors in industrial automation

Technological advances have made today's ultrasonic sensors rugged and precise, making them simpler, more flexible and more cost-effective. These new features have opened up a new field of application that goes beyond the traditional ultrasonic sensor. Today's ultrasonic sensors offer mechanical designers a new and creative solution for the industrial sector. A few years ago, ultrasonic sensors were the backup option in sensor technology, and designers chose them only when other sensing technologies failed to work, such as detecting transparent objects, sensing over long distances or when the target color changed. New technologies have made today's ultrasonic sensors able to withstand harsh environments, such as ultrasonic sensors with IP67 and IP69K protection levels that can be used in humid environments; sensors with built-in temperature compensation circuits that calibrate when there are significant temperature changes during normal or changing operating conditions; Teflon models have a special coating on the surface that can be used to resist the erosion of harmful chemicals; advanced filtering circuits allow ultrasonic sensors to shield against field interference; new sensor heads have stronger self-protection capabilities that can resist material damage and adapt to relatively dirty environments. Ease of use of ultrasonic sensors A notable feature of the new generation of ultrasonic sensors is that they are easier to use, including button settings, DIP switch programming and some multiple program options. The switch button is completely embedded in the sensor device, which makes it very easy to adjust the distance of the sensor installation. It is a simple matter to place the target in front of the sensor and press the button. The sensor can automatically master the size of the window and the distance. Easy installation means that the same sensor can be adapted to many different applications. The programming method of DIP switches means that a simple sensor can be customized for certain special applications. These personalized features include response time, output type, switch and analog selection, and special settings for level/liquid level control. Ultrasonic sensors generally include multiple output types in a single sensor. Models with two switch outputs can use a sensor to sense two objects at different distances at the same time, while models with one switch output and one analog output can be used to measure and provide alarm outputs. The above features make ultrasonic sensors more flexible and selective than sensors with other technologies. Basic principles for using ultrasonic sensors Ultrasonic sensors use the vibration of the pressure-vibration ceramic on the sensor head to generate high-frequency sound waves that are inaudible to the human ear for sensing. If the sound wave hits an object, the sensor can receive the return wave. The sensor can determine the distance of the object by the wavelength of the sound wave and the time difference between the emission of the sound wave and the reception of the return sound wave. More typically, a sensor can have two settings, short distance and long distance, through the setting of a button, and the sensor can detect the object regardless of the boundary. For example: an ultrasonic sensor can be installed on a pool of liquid or a box of small balls, and send sound waves to the container. By the length of time it takes to receive the return wave, it can be determined whether the container is full, empty or partially full. Ultrasonic sensors also use models with independent transmitters and receivers. When detecting slow-moving objects or in humid environments, this type of ultrasonic sensor with a beam indication is very suitable. Ultrasonic sensors are the first choice when detecting transparent objects, liquids, smooth, rough, shiny translucent materials and other surfaces, as well as irregular objects. Ultrasonic sensors are not suitable for outdoor use, extremely hot environments, pressurized containers, and objects with foam. Ultrasonic sensor selection points Range and size The size of the object being detected will affect the maximum effective range of the ultrasonic sensor. The sensor must detect a certain level of sound waves before it can be stimulated to output a signal. A larger object can reflect most of the sound waves to the sensor, so the sensor can sense the object to its maximum extent, while a small object can only reflect a small amount of sound waves, which significantly reduces the sensing range. Object to be measured The most ideal object that can be detected by ultrasonic sensors should be large, flat, high-density objects, placed vertically facing the sensor sensing surface. The most difficult objects to detect are those with very small areas, or made of materials that can absorb sound waves, such as foam plastics, or facing the sensor at an angle. Some objects that are more difficult to detect can be taught to the background surface of the object first, and then respond to the object placed between the sensor and the background. When used for liquid measurement, the surface of the liquid needs to face the ultrasonic sensor vertically. If the surface of the liquid is very uneven, the response time of the sensor should be adjusted longer. It will average these changes and can read more fixedly. Using the ultrasonic sensor in Retrosonic mode also makes it possible to detect irregular objects. In Retrosonic mode, the ultrasonic sensor can first detect a flat background, such as a wall. When any object passes between the sensor and the wall, it will block the sound waves. The sensor senses the interruption and realizes that an object has appeared. Vibration Vibration of both the sensor itself and the surrounding machinery will affect the accuracy of distance measurement. At this time, you can consider taking some vibration reduction measures, such as using a rubber anti-vibration device to make a base for the sensor to reduce vibration, and using a fixing rod can also eliminate or minimize vibration. Attenuation When the ambient temperature changes slowly, the temperature-compensated ultrasonic sensor can make adjustments, but if the temperature changes too quickly, the sensor will not be able to make adjustments. False positives Sound waves may be reflected by some nearby objects, such as rails or fixing fixtures. In order to ensure the reliability of detection, the influence of surrounding objects on the sound wave reflection must be reduced or eliminated. In order to avoid false detection of surrounding objects, many ultrasonic sensors have an LED indicator to guide the operator during installation to ensure that the sensor is installed correctly and reduce the risk of errors. Typical Application Examples of Ultrasonic Sensors Ultrasonic sensors were once considered too difficult or too expensive to operate, but as costs have fallen and they have become easier to use, more and more mechanical designers have incorporated ultrasonic sensors into their machine designs. Industrial applications of ultrasonic sensors include detecting fill conditions, detecting reflective objects and materials, controlling the expansion of loops, and measuring distances. The use of ultrasonic sensors in industry is developing rapidly. This once expensive and inaccurate technology has now become simple, accurate, and inexpensive. Ultrasonic sensors have become a routine device in process control to improve product quality, used to detect defective products, confirm the presence or absence of products, and other areas. This sensor can also improve productivity, it can reduce waste, and avoid downtime due to broken parts. The future development of such products in this technology field will continue this trend. This is a challenge, but there is a consensus in the industry that ultrasonic sensors have great development potential in all manufacturing fields, including quality control, process control and detection.